TECHNICAL MANUAL OPERATOR S, ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS UST) FOR

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1 TECHNICAL MANUAL OPERATOR S, ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS UST) FOR MILLING MACHINE MODEL NO. 4 (BURKE DIVISION POWERMATIC/HOUDAILLE, INC.) (NSN ) This publication is a courtesy quick copy from the UNITED STATES ARMY PUBLICATIONS CENTER, ST. LOUIS, MISSOURI, to meet your needs while we are replenishing our regular stock. HEADQUARTERS, DEPARTMENT OF THE ARMY JULY 1981

2 Technical Manual HEADQUARTERS DEPARTMENT OF THE ARMY No &P Washington, DC, 15 July 1981 OPERATOR S, ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL (INCLUDING FOR MILLING MACHINE MODEL NO. 4 (NSN ) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to Improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form , located in the back of this manual direct to: Commander, US Army Armament Materiel Readiness Command, ATTN: DRSAR-MAS, Rock Island, IL A reply will be furnished direct to you. NOTE This manual is published for the purpose of identifying an authorized commercial manual for the use of the personnel to whom this milling machine is issued. Manufactured by: Burke Division Powermatic/Houdaille, Inc. 38 Brotherton Road Cincinnati, OH Procured under Contract No. DAAA09-78-C-5160 This technical manual is an authentication of the manufacturers commercial literature and does not conform with the format and content specified in AR 310-3, Military Publications. This technical manual does, however, contain available information that is essential to the operation and maintenance of the equipment. i

3 INSTRUCTIONS FOR REQUISITIONING PARTS NOT IDENTIFIED BY NSN When requisitioning parts not identified by National Stock Number, it is mandatory that the following information be furnished the supply officer. 1 - Manufacturer s Federal Supply Code Number Manufacturer s Part Number exactly as listed herein. 3 - Nomenclature exactly as listed herein, including dimensions, if necessary. 4 - Manufacturer s Model Number - Model No Manufacturer s Serial Number (End Item) 6 - Any other information such as Type, Frame Number, and Electrical Characteristics, if applicable. 7 - If 00 Form 1348 is used, fill in all blocks except 4, 5, 6, and Remarks field in accordance with AR Complete Form as Follows: (a) In blocks 4, 5, 6, list manufacturer s Federal Supply Code Number followed by a colon and manufacturer s Part Number for the repair part. (b) Complete Remarks field as follows: Noun: (nomenclature of repair part) For: NSN: Manufacturer: Burke Division Powermatic/Houdaille, Inc. 38 Brotherton Road Cincinnati, OH Model: No. 4 Serial: (of end item) Any other pertinent information such as Frame Number, Type, Dimensions, etc. ii

4 INDEX Setting Up the Machine...page 2 Lubricating Instructions...page 2 Operating Instructions...page 3 Cross Section Sketches: Column Assembly...page 4 Knee, Saddle, and Table Assembly...page 5 Gear Box; One Inch Arbor...page 6 Switch; Guard; Motor...page 7 Quick Opening Vise; Plain and Swivel Vise...page 8 Vertical Milling Attachment...page 9 Universal Saddle; Tailstock...page 10 Indexing Centers...page 11 Wiring Diagram...page 12 Parts List...page Attachments...page 17 1

5 TM &P SETTING UP THE MACHINE The #4 Milling Machine is an accurate machine tool. It should be carefully handled at all tines. The most satisfactory manner of moving the machine after it has been uncrated is to fasten ropes under both the front and rear of the overarm, and gently lift it with a crane. Extreme caution should be used to avoid jarring, dropping, or nicking any of the surfaces. For optimum results be sure that the machine is leveled and rigidly secured. Before operating, remove the protective shipping sludge with clear gasoline; oil the bearing surfaces and lead screws. If available, it is suggested that the excess gasoline be blown off with compressed air. Be sure to clean all particles of dirt from inside the spindle opening, and use equal care in cleaning the tapered shank of the drive arbor. LUBRICATING INSTRUCTIONS Machine: The spindle of the #4 Milling Machine is equipped with grease-lubricated roller bearings. The proper amount of lubricant has been applied at the factory. Every month, or after approximately 150 hours of operation, additional grease should be added. Use-grease similar to Lubriplate #310. Each time the spindle is lubricated add a small amount of the same grease to the gear box. All moving parts, including lead screws, shafts, and the knee, saddle, and table ways should be oiled after each day s operation. Any good grade of lubricating oil may be used for this purpose. Motor: Ball bearing gearhead motors provided with these Milling Machines are lubricated at the factory. Every 1000 hours of operation, (usually six months), additional lubricant should be added. Use any good grade of ball bearing grease, but do not over-lubricate. 2

6 OPERATING INSTRUCTIONS TM &P The operation of the #4 Milling Machine is so simple that no specific instructions are required. For possible assistance, the following is suggested: Spindle Speeds: To change spindle speeds, raise the motor, place the driving V belt in the proper groove on the motor pulley and in the corresponding groove on the spindle pulley. The smallest groove on the motor pulley produces the slowest spindle speed. Power Feed Speeds: There are four alternative longitudinal table feed speeds for each spindle speed. The smallest groove on the power feed drive pulley (attached to the spindle) provides the slowest table feed. Power Feed: To engage the power feed, depress the power feed pawl (part B-713) while the motor is running. Throwouts (parts B-723) may be set to disengage the power feed automatically where desired. The table feed may also be stopped by turning off the motor or by manually disengaging the pawl. Reversing the motor will reverse the direction of table travel. Gib Adjustment: Adjustable gibs are provided between the table and saddle (table gib), saddle and knee (saddle gib), and knee and column (knee gib). The saddle and knee gibs are each provided with three adjusting screws, the center one of which is the lock screw. After the machine has been set up for a particular horizontal milling operation, lock the saddle and knee gibs in place. This will assure additional rigidity. The table gib is provided with four adjusting set screws and nuts. The tension on each of these screws should be approximately the same, with the nuts tightened in place to maintain constant torque. Starting Switch: To reverse the direction of rotation of the motor, turn the drum type switch handle to the neutral position, and allow the motor to come to a complete stop. Then turn the switch handle to the reverse position. 3

7 COLUMN ASSEMBLY B Column B-525 Bearing. cup (front) B-112 Overarm Bracket B-526 Bearing. cone (front) B-113 Stud, Power Feed Arm M-527 Bearing. cup (rear) B-117 Spindle Pulley M-528 Bearing, cone (rear) B-118 Bearing, for power feed arm B-529 Lubricant retainer (outside front) B-121-A Arm, power feed B-530 Lubricant retainer (outside rear) B-121-C Bushing, power feed arm B-531 Plastic retaining rings (2) D Spindle B-532 Plastic retaining rings (2) B Spindle B-533-E Seal (felt) B-123 Pulley. power feed B-533-R Seal (felt) B-148 Arbor Center B-534 Seal* (felt) (2) B-155 Spindle adjusting nuts B-850-A Overam Clamp Screws (Not shown) B-169 Bushing, spindle spacing M-151 Screw-Handles (2) B-170 Overarm B-598 Binder Bolt B-209 Motor Bracket B-701-A Universal Joint B-251 Oil Pan B-708 Sleeve B Draw Bar B-721 Pulley-power feed (driven) B-508 V belt (Motor to spindle) B-727 V belt (Power feed) 4

KNEE, SADDLE and TABLE ASSEMBLY TM 9-3417-215-14&P B-100 Column B-215 Ball crank handle B-105 Thrust Bearing B-216 Bushing, table feed B-106 Handwheel B-218 Dial, table feed B-114 Gib, saddle B-251

8 KNEE, SADDLE and TABLE ASSEMBLY TM &P B-100 Column B-215 Ball crank handle B-105 Thrust Bearing B-216 Bushing, table feed B-106 Handwheel B-218 Dial, table feed B-114 Gib, saddle B-251 Oil pan B-115 Nut, crossfeed B-290 Collar for screw B Nut, vertical feed M-505-B Hex nuts B Bushing, crossfeed B-705 Bronze worm gear B Knee B-710 Throwout cam B-126 Table B-712 Trip rod collar B-128 Screw, vertical feed B-714 Trip rod spring B Screw, crossfeed B-722 Trip rod bearing brackets (2) B-130 Shaft, vertical feed B-723 Trip rod throw-outs (2) B-140 Gib, table B-724 Trip rod finger B-141 Gib, knee B-725 Trip rod B-152 Pinion Gear B-954 Tapered Pin B-213 Screw, table feed B-214 Nut, table feed 5

9 GEAR BOX - POWER FEED Gear Box Power Feed B-113 Stud, power feed arm B-707 Telescope tube B-121-A Arm, power feed B-709 Telescope shaft B-701 Universal joint B-713 Pawl, power feed B-701-A Universal joint B-713-P Plate, power feed pawl B-702 Yoke, Gear Box B-715 Spring, gear box B-704 Steel Worm B-718 Stud, yoke B-706 Gear Box B-719 Worm Shaft B-706-C Gear Box Cover B-800 Oiler ONE INCH ARBOR One Inch Arbor B-102-C One Inch arbor M-200 Arbor nut M inch spacer collar M inch spacer collar M-228 1/2 inch spacer collar 6

10 SWITCH, GUARD and MOTOR Switch, Guard, and Motor B-18Z Motor Pulley B f Spindle belt guard (front) B r Spindle belt guard (rear) B-210 Motor Mounting Bracket M Connector M-267 Flexible Conduit B-500 Motor B-501 Drum type switch B-503 Stud, motor bracket 7

11 QUICK OPENING VISE Quick Opening Vise B-W-10 Wrench B-300-Q Vise Body B-303-Q Vise Handle B-304 Jaw (Body) B-305 Jaw (Slide) B-306-Q Slide B-308 Tongue Strips B-309 Handle Bushing B-310 Link PLAIN VISE and SWIVEL VISE Plain Vise and Swivel Vise B-300 Vise Body B-301 Slide Clamps B-303 Handle B-304 Jaw (Body) B-305 Jaw (Slide) B-306 Slide B-307 Screw B-330 Swivel Base B-331 Swivel Base Plug Note: The swivel vise includes the plain vise assembly plus the swivel base and plug. 8

12 VERTICAL MILLING ATTACHMENT Vertical Milling Attachment B-2 Vertical Head Casting B-3 Adapter Plate B-5 Driving Arbor B-6 Bronze Bushing. B-6-C Steel Plate (2) B-7 Steel Pinion Gear B-9 Bronze Spiral Gear B-10 Binder Bolt B-11 Spindle B-14 Ball Bearings (Front) B-15 Ball Bearings (Rear) B-23 Draw-in Sleeve B-24 Eccentric Bushing M-26 Spanner Wrench B-2841 Ball Bearing (2) (Not shown) 9

13 UNIVERSAL SADDE FOR No. 4 MILLING MACHINE Universal Saddle for #4 Milling Machine B-107 Swivel Plate B-108 Swivel Stud B-114 Saddle Gib B Cross Feed Nut B-15-U Universal Saddle B-140 Table Gib B-214 Table Feed Nut M-958 Gib Locking Screw TAILSTOCK for INDEXING CENTERS and DIVIDING HEAD Tailstock for Indexing Centers and Dividing Head B-615 Tailstock B-616 Tailstock Center B-618 Tailstock Screw B-619 Handwheel for Screw B-620 Clamping Screw B-800 T Slot Bolt B-800-N T Slot Bolt Nut 10

14 TILTING HEAD INDEX CENTER WITH COLLET SPINDLE M-25 ½ inch Collet B-155 Spindle Adjusting Nut B-601 Tilting Head Index Center B-602 Body Bracket B-603 Back Plate B-604-A Collet Type Spindle B-605 Plunger Finger B-606 Plunger Bracket B-607 Pawl Lever B-608 Spring B-610 Index Plate B-613 Draw-in-Sleeve STATIONARY HEAD INDEX CENTER WITH TAPERED SPINDLE B-600 Stationary Head Index Center B-604-B Tapered Type Spindle B-610 Index Plate B-611-T Tapered Center B-612 Driving Dog B-905 Set Screws 11

15 WIRING DIAGRAM - ELECTRICALLY REVERSIBLE GEARHEAD MOTORS TM &P THREE LEAD MOTORS FOUR LEAD MOTORS 12

16 PARTS LIST N6.4 MILLING MACHINE TM &P less motor and electrical equipment MATERIALS C.I. = cast iron ALUM. = aluminum C.R.S = cold rolled steel COM. = purchased Req d Part No. Name UNIT-COLUMN ASSEMBLY 1 B Column (C.I.) 1 B 113 Stud. power feed arm (C.R.S.) 1 B 117 Spindle Pulley (C.I.) 1 B 118 Collar1 power feed stud arm (C.R.S.) 1 B 121-A or L Power fed arm (with B 121-C bushing) (C.I.) 1 B Spindle, #9 B & S Taper (alloy steel) 1 B 123 Pulley, power feed ( die cast) 2 B Spindle Adjusting Nuts (1-1/4"-20 Hex jam) (C.R.S.) 1 B 169-S or L Bushing. spindle spacing (C.R.S.) 1 B 170 (SA) Overarm Sub Assembly (C.R.S. & C.I.) 1 B 182 Motor Pulley (C.I. or aluminum) 1 B 20Z-4F Guard. motor side (sheet metal) 1 B 202-4R Guard, cast iron (C.I.) 1 B 209 Motor Bracket (C.I.) 1 B 210-A,B or C Motor Frame (C.I.) 1 B 251 Oil Pan (C.1.) 1 B 503 Motor Stud (C.R.S.) 1 B 508 V Belt, Motor (#230-B) (COM.) 2 M 509 7/16" x 1-1/2 Hex Head Cap Screws (COM.) 1 M 513 5/16 x 3/4" Allen Set Screw (COM.) 5 M 517 3/8 x 1" Hex Head Cap Screws (COM.) 2 B 520 #11 Woodruff Keys (COM.) 2 M 523 1/8" Zerk Fittings (COM.) 1 B Cup, Timken (front) (COM.) 1 B Cone, " to (COM.) 1 M Cup, " (rear) (COM.) 1 M Cone, " " (COM.) 1 B 5Z9 Front Outside Seal (Fibre) (COM.) 1 B Rear " (COM.) 2 B 531 Front Inside (COM.) 2 B 532 Rear (COM.) 1 B 533-F Oil Seal (Felt) (COM.) 1 B533-R (COM.) 2 B 534 (COM.) 1 M 563 5/8" Cad Washer (COM.) I M 583 1/2" Hex Half Nut (COM.) 1 B 7Z0 Washer, fibre (COM.) 3 M 908 5/16" x 3/4" Hex Head Cap Screws (COM.) 1 M 928 5/8" x 2-3/4" Hex Head Cap Screws (COM.) 6 M /24" x 1/2" Round Head Machine Screws (COM.) 2 M 948 3/8" x 1/2" Allen Set Screws (COM.) 4 M 951 1/2'' x 1" Hex Head Cap Screws (COM.) 13

17 UNIT-TABLE ASSEMBLY 1 B 126 Table (Specify size desired) (C.I.) 1 B 213 Table Feed Screw (Conforms to table length) (C.R.S.) 1 B 215 Ball Crank, 5" (COM.) 1 B 216 Bush, table feed (Brass) 1 B 218 Dial, " " (Graduated.100) (C.R.S.) 1 M 505 3/8" Hex Half Nut (COM.) 2 M 534 1/4" x 3/4" Fillister Head Cap Screws (COM.) 1 M 543 #8 Woodruff Key (COM.) 1 B 701-B Universal Joint (COM.) 1 B 706-A Gear Feed Box Sub Assembly (See SA) 1 B 707 Telescope Tube (C.R.S.) 1 B 708 Sleeve, pulley driven (C.R.S.) 2 B 720 3/4" I.D. x 1-5/16" O.D. Fibre Washers (COM.) 1 B 721-A Pulley, power feed (die cast) 1 B 725-A or B(SA) Throw Out Rod, power feed, (Sub Assembly) (see SA) 1 B 727-A or B V Belt, power feed (Conforms to table length) (COM.) 3 M /24" x 1/4" Allen Set Screws (COM.) 3 M 939 1/4" x ¼ " " (COM.) 2 M 963 #2 Woodruff Keys (COM.) UNIT-KNEE ASSEMBLY 1 B Knee (C.I.) 1 B 105 Thrust Bearing (COM.) 2 B 106 (SA) Handwheel Sub Assembly (Graduated.100) (see S.A.) 1 B Cross Feed Nut (Brass) 1 B Cross Feed Bushing (Bronze) 1 B (SA) Vertical Feed Screw Sub Assembly ( see S.A.) 1 B Cross Feed Screw (C.R.S.) 1 B (SA) Vertical Feed Shaft Sub Assembly ( see S.A.) 2 B 131 Cross Feed Screw Lock Nuts (5/8"-22 Hex Jam) (COM.) 1 B 141 Gib, Knee (C.I.) 1 B Pinion gear, vertical feed (C.R.S.) 3 M 505 3/8" Hex Half Nuts (COM.) 3 M 507 3/8" Lock Washers (COM.) 2 M 543 #8 Woodruff Keys (COM.) 3 M 919 3/8" x 1-1/4" Hex Head Cap Screws (COM.) 2 M 939 1/4" x 1/4" Allen Set Screws (COM.) UNIT-SADDLE ASSEMBLY 1 B Saddle (C.I.) 3 B 104 Beveled Gib Pins (table) (COM.) 1 B 114 Gib, Saddle (C.I.) 1 B 140 Gib, Table ( C.I.) 1 B 214 Nut, Table Feed (Bronze) 1 M 597 5/16" Hex Half Nut (COM.) 1 B 710 Cam, Power feed throw out (C.R.S.) 2 M 905 5/16" x 3/4" Fillister Head Cap Screws (COM.) 1 M /16" Square Head Set Screw (Cup Point) (COM.) 3 M 938 1/4" x 3/4" Allen Set Screws (COM.) 2 M 955 5/16" Lock Washers (COM.) 14

18 2 M 956 5/16" x 1" Hex Head Cap Screws (COM.) 3 M 957 1/4" Hex jam Nuts (Brass) 1 M /4" x 1" Round Head Machine Screw (COM.) 1 M 959 1/4" x 1/2" Flat Head Machine Screw (COM.) 1 M 960 1/8" x 3/4" Straight Pin (COM.) TM &P Sub Assemblies, for #4 Miller Req d Part No. Name B 706 (SA) UNIT-POWER FEED ASSEMBLY 2 M 516 5/16" x 7/8" Fillister Head Cap Screws (COM.) 1 B 701 Universal Joint (1/2" Ream Both Ends) (C.R.S.) 1 B 702 Yoke, Power Feed (Bronze) 1 B 704 Steel Worm (C.R.S.) 1 B 705 Worm Gear, (Bronze) 1 B 706 Gear Box, Power Feed (ALUM.) 1 B 706-C Cover, Gear Box (ALUM.) 1 B 709 Shaft, Telescope (C.R.S.) 1 B 713 Pawl, Power Feed (C.l.) 1 B 713-P Plate, Pawl (C.R S.) 1 B 715 Spring, Gear Box (Steel) 1 B 718 Stud, Yoke (C.R.S.) 1 B 719 Shaft, Worm (C.R.S.) 2 B 726 1/2" I.D. x 3/4" O.D. Fibre Washers (COM.) 3 M /24" x 1/4" Allen Set Screws (COM.) 4 M /24" x 1/2" Round Head Machine Screws (COM.) 1 M /24" Hex Half Nuts (Brass) 2 M 964 #2 x 3/4" Tapered Pins (COM.) B 106 (SA) HANDWHEEL SUB ASSEMBLY 1 B 106 Handwheel (Graduates.100) (C.I.) 1 B 106-H Handle, Handwheel (COM.) 1 M911 1/4" x 1/2" Allen Set Screw (COM.) B (SA) VERTICAL FEED SCREW SUB ASSEMBLY 1 B Vertical Feed Nut (Bronze) 1 B " Screw (C.R.S.) 1 B 128-4C " Collar (C.R.S.) 1 M954 #3 x 1-1/4" Tapered Pin (COM.) B (SA) VERTICAL FEED SHAFT SUB ASSEMBLY 1 B Vertical Feed Shaft (C.R.S.) 1 B " " Pinion (C.R.S.) 1 M954 #3 x 1-1/4" Tapered Pin (COM.) B 170 (SA) OVERARM SUB ASSEMBLY 1 B 112 Overarm Bracket ( C.l.) 1 B 148 Center, Overarm Bracket (1/2" straight shank) (C.R.S.) 1 B 170 Overarm (C.R.S.) 1 M 948 3/8" x 1/2" Allen Set Screw (COM.) 15

19 B 725 (SA) TRIP ROD SUB ASSEMB1LY 1 B 712 Trip Rod Collar (C.R.S.) 1 B 714 " Spring (Steel) 2 B 722 " Bearing Brackets (ALUM.) 2 B 723 " Throw Outs (C.R.S.) 1 B 724 " Finger (C.R.S.) 1 B 725-A or B Trip Rod (C.R.S.) 2 M 939 1/4" x 1/4" Allen Set Screws (COM.) 4 M 960 1/8" x 3/4" Straight Pins (COM.) Note: B725-A Trip Rod is for 16" table only 8725-B Trip Rod is for 20" table only When #B 77-D (28") Cabinet Column is required for any machine it includes the following parts: 1 B 77-D Cabinet Column, 28" (C.I.) 1 B 101 (SA) Column Door Sub Assembly (C.R.S.) 1 M 515 5/16" x 1/2" Thumb Screw (Parker Kalon) 4 M 551 1/2" Hex Full Nuts (COM.) 4 M 904 1/2" Lock Washers (COM.) 4 M 922 1/2" x 3" Hex Head Cap Screws (COM.) 1 M 955 5/16" Flat Washer (COM.) #4 Universal Mill1vess motor and electrical equipment. Req'd Part No. Name Note: All parts are the same as a standard 04 Plain Miller except for, the following changes. MINUS 1 B Saddle (C.I.) 1 B 701-A Universal joint (C.R.S.) 1 B 708 Sleeve, pulley driven (C.R.S.) 1 B 721-A Pulley, power feed (die cast) PLUS THE FOLLOWING PARTS 1 B 107 Plate, Swivel (C.I.) 1 B 108 Stud, Swivel (C.R.S.) 1 B 125-U Saddle, Universal (C.I.) B 701-U Universal Joint (1/2" x 9/16" Ream) (C.R.S.) 1 B 708-U Sleeve, pulley-driven (C.R.S.) B 721-B Pulley, Power Feed (die cast) 1 B 728 Shaft, Splined (C.R.S.) 2 M 921 1/2" x 1-1/2" Hex Head Cap Screws (COM.) 2 M 925 1/2" Cad Washers (Cr1.) 16

20 Attachments for MILLERS and other small Machine Tools 17/(18 blank)

21 By Order of the Secretary of the Army: Official: E. C. MEYER General, United States Army Chief of Staff ROBERT M. JOYCE Brigadier General, United States Army The Adjutant General

23 PIN:

HYDRAULIC CONTROL DETAILS PARTS LIST

Always give model number, serial number and part number when ordering repair parts. HYDRAULIC CONTROL DETAILS PARTS LIST REF NO. PART NUMBER DESCRIPTION 1 101939 Hydraulic Tank 2 101940 Hydraulic Tank